Production Control.

Control comes in after, a particular plan has been made for implementation.

Production Control, Introduction
 It

is one of the most important and fundamental function of an enterprise.  It ensures desired output as per specified quality, quantity and timings in most economical way.  Planning prescribes and outlines the objectives and provide guidelines.

Production Control, Introduction
 It’s

the production control which directs and regulates all activities of production process.  Control is a management process which constrains events to follow plans.  Control is a dynamic activity which sees that facilities and personnel are economically utilized and the products are manufactured within the time and cost limits.

Production Control.
 Dictionary

meaning of Control is to organize or to Check and Regulate.  Definition.

“ Control is maintaining a balance in activities towards a goal or set of goals evolved during production planning.”
 Control

is necessity, not luxury,  Control is investment not expense.

Production Control.
 ii. iii. iv. v. vi. vii.

Objectives (Functions) of PC dept. Provision of Raw M, Machines and Labor. Organize production as per demand. OUR, to minimize cost and meet delivery. Economize prod. and minimize setup cost. Co-ordination of various operations. Ensure timely supply of raw material of desired Qlty and Qty, to avoid delay.

Production Control.
 ii.

iii.

Contd… Perform inspection of semi-finished and finished goods and use quality control techniques. Responsible for product design and development.

Production Control.

Factors Determining Production Control Operations. Nature of Production. Nature of activities. Magnitude of operation.

3. 4. 5.

Production Control.

LEVELS of PRODUCTION CONTROL.

2. 3. 4. 5. 6.

Programming Ordering Dispatching Progressing/ Follow up Inventory control.

Levels/ Techniques of Prod. Control
 

Programming. Regulates the supply of finished product in desired amount at due date as per plans. It ensures most efficient use of labor, equipment and capital. There are 3 main decisions involved in Programming Viz.

Levels/ Techniques of Prod. Control

DECISIONS Nature of product to be manufactured. Amount of quantities to be produced. When to produce.

3. 4. 5.

Levels/ Techniques of Prod. Control

Objectives of Production Programming.

Reliable delivery to customer. 4. EVEN loading of plant. 5. EVEN loading of Labor in hours per week. 6. Efficient use of Capital. Ex:- layout of Production program.
3.

Levels/ Techniques of Prod. Control

2. 3. 4.

In preparation of Production program 3 main problems are solved. Smoothing of seasonal sales demand. Choice of batch quantity and batch frequency for products, as per requirement. Constant revision of production Program to keep in line with the sales program.

Levels/ Techniques of Prod. Control
I.

ORDERING
It is the process of placing orders to the suppliers and processing departments for the materials required in such a way that all items are delivered in time to meet the production program. The order authorizing production is what has come to be known as WORKS order. It is derived from master schedule and operation sheets.

Levels/ Techniques of Prod. Control
 2.

2 information are required for each order Requirement Quantity:

This information can be gathered from Master Schedule. Generally it is as same as Requirement Quantity but sometimes for regular use higher quantity is ordered. It is very critical decision to be taken.

3.

Order Quantity:

Levels/ Techniques of Prod. Control

Rules to be observed in ordering system No work can be ordered without an order. All orders should be in writing and in standard form. (For purchase or manuf) All orders should be issued by authorized authority.

3. 4. 5.

Levels/ Techniques of Prod. Control
 2. 3. 4. 5. 6.

Following are main decisions in Ordering. Desired quantity of various components and delivery date. How much to order? When to issue an order? In what quantity parts should be procured. Nature of Components (prodct, scrap,spare

Levels/ Techniques of Prod. Control COMPONENTS OF ORDER FORM

 Order

number.  Date of Order  Ordered by  Production Center.  Part number.

 Part

Description  Order Quantity  Run Quantity  Due Date  Material Source.  Delivery instructions

Levels/ Techniques of Prod. Control
I.  

Dispatching. The decision of assigning various jobs to different machines is known as dispatching Once the job is in the area where operation is to be done, dispatching decides where and by whom the job is to done.

Levels/ Techniques of Prod. Control
 2. 3. 4. 5. 6.

Functions of Dispatching. To check immediate availability of R.M. Ensuring all the production and inspection aids are available for use. Obtain appropriate specification list. To collate jobs and all activities. Processing inspection schedule.

Levels/ Techniques of Prod. Control
 2. 3. 4. 5. 6.

Contd… Assign work to proper man, machine & plc. Issue necessary material when needed. Issue production order note stating start and finish times. Return the acquired material at right place and time. Maintain all production records.

Levels/ Techniques of Prod. Control
important documents in production control through dispatching.
1. 2. 3. 4. 5.

Job order Store requisition Issue of tool orders Issue of time tickets Issue of inspection orders.

 Collection

of time tickets at the end of operations.  Recording idle times of machines.  Internal delivery notes of finished goods and R.M. back to stores.

Levels/ Techniques of Prod. Control
I. 

Progressing or Follow-up. It is checking of production activities systematically so that production is carried out as per plans. It is a function by which one can give an early warning when actual production is deviating from planned production.

Levels/ Techniques of Prod. Control
 2. 3. 4. 5. 6.

NECESSITY / IMPORTANCE of Follow-up Failure to deliver material on time. Machine/Power break-down. Employees absenteeism. Errors of design, planning or human activity Unnecessary delays/ bottlenecks.

Levels/ Techniques of Prod. Control

Generally specialists known as progress chasers act as watch-dogs, doing.. Checking the progress continuously Cause of discrepancy, if any in performance Authorizing and signing requisitions. Liason with other departments.

3. 4. 5. 6.

Levels/ Techniques of Prod. Control

Steps in Progressing or Follow-up. Flow charts indicating the planned sequence of operations. Production schedules to compare actual with targets. Machine loading charts. Inspection schedules to check deviations.

3. 4. 5. 6.

Levels/ Techniques of Prod. Control
I.   4. 5.

INVENTORY CONTROL Inventory for any organization is necessary evil and requires careful planning. Components of Inventory are:All materials, parts, WIP or finished goods recorded & kept it stores or warehouse. List of quantities/monetary values for all goods.

Levels/ Techniques of Prod. Control

OBJECTIVES of Inventory Control. Protection against fluctuation in demand. Better use of Men, Machines and Materials. Protection against Fluctuation in Output.

3. 4. 5.

Levels/ Techniques of Prod. Control

Inventory Control solves out 3 major issues, Optimum amount of inventory to be carried Economic Lot Size. Choice of an Ideal system of inventory control.

3. 4. 5.